Fully automated self-service store

ABSTRACT

An automated self-service store is disclosed including a shopper accessible level having inventory for selection by a shopper, and an item storage and replenishment area for storing inventory. The self-service store further includes mobile robots for replenishing inventory at the shopper accessible level from the item storage and replenishment area.

PRIORITY CLAIM

The present application claims priority to U.S. Provisional PatentApplication No. 62/509,875, filed on May 23, 2017, entitled “FULLYAUTOMATED SELF-SERVICE STORE,” which application is incorporated byreference herein in its entirety.

BACKGROUND

An order-fulfillment system for use in supply chains, for example inretail supply chains, may fulfill orders for individual product units,referred to herein as “eaches” (also called “pieces”, “articles”,“items” or, generally, any articles available for purchase in retail asa purchase unit, etc.), which are typically packaged and shipped by themanufacturer in containers known as “cases”. The “each” as used hereinfor convenience purposes, may be considered the most granular unit ofhandling in retail supply chains. In conventional retail outlets,consumers pick eaches off of shelves. When an each is out of inventory,there is no ability to restock that article in real time. Additionally,there is no effective system at tracking what eaches a consumer hasselected for purchases, other than traditional check out methods whereconsumers wait in line and each item is then scanned and registered.

DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings.

FIG. 1—Fully automated retail store where shoppers pick items directlyfrom totes, sometime containing subtotes.

FIG. 2—Another view of shopping aisles within the fully automated retailstore.

FIG. 3—Mobile robot is shown replenishing tote in shopping store aisle.

FIG. 4—Shopper using finger mounted or key-fob RFID reader is shown toread item them are purchasing from tote.

FIG. 5—Racks containing totes are shown automatically transported bypallet bots from trailers and docked to mobile robot rails extending outof the tote storage structure.

FIG. 6—Mobile robot is shown retrieving a tote containing incomingproducts from the tote rack.

FIG. 7—Another view of mobile robot retrieving tote from tote rack.

FIG. 8—An articulated arm robot is shown moving the totes from thepallet to shelf locations where the mobile robots can retrieve the totesand transfer them into the storage structure.

FIG. 9—Mobile robots are shown accessing any of the tote storage aisles.

FIG. 10—Side Elevation View of Fully Automated Retail Store.

FIG. 11—Plan View of Fully Automated Retail Store.

FIG. 12—Front Elevation of Fully Automated Retail Store.

FIG. 13—Fully Automated Distribution Center.

FIG. 14—RFID Reader Flow Diagram.

FIG. 15—Alternative configuration of system without storage overshopping aisles. This configuration permits skylights to lightenshopping aisle.

FIG. 16—Shopping stations are shown where totes are presented toshoppers based on their specific order or request.

FIG. 17—Shopping stations are shown in a parking structure where totesare presented to shoppers based on their specific order or request.

FIG. 18—Alternative configuration of way to mount racks is showncontaining totes to the storage array.

DETAILED DESCRIPTION

The present technology will now be explained with reference to thefigures, which in general relate to an automated self-service retailstore. Referring initially to FIGS. 1 and 2, there is shown a portion ofan automated self-service retail store 100. The store 100 includes ashopper-accessible area 102 including multiple aisles 104 having totes106 from which a shopper 110 can select eaches for placement in hershopping cart. The aisles 104 may include flat panel monitors 112describing the eaches within a tote 106. The flat panel monitors may beother input terminals, such as displays, or interactive touchscreens,providing the price and information about items in the totes beneaththem.

The store 100 may further include an item storage and replenishment area122 positioned above the shopper-accessible area 102. The item storageand replenishment area 122 stores totes 106 in storage racks 128 forreplenishing totes 106 in the shopper-accessible area 102. The storageracks are in turn connected to rails along which the mobile robots 124travel. The totes 106 are automatically delivered by mobile robots 124to the shopper-accessible area 102, for example when a tote inshopper-accessible area 102 is empty. At the same time, the iteminformation above the tote is updated on the flat panel monitor. Therobot 124 may replenish an empty tote 106 with the same or a differentitem. A central Material Control System (MCS) 114 controls the mobilerobots and also updates the information above the totes. The MCS 114 maycontrol when totes 106 in the shopper-accessible area 102 arereplenished and with what. The MCS may also keep track of items removedfrom totes 106 by a shopper 110 as explained below.

FIGS. 1 and 2 show a single shopper-accessible area 102 positionedbeneath the item storage and replenishment area 122. However, in furtherembodiments, the item storage and replenishment area 122 may be below,or on the same level as the shopper-accessible area 102. Additionally,in further embodiments, there may be multiple levels ofshopper-accessible areas 102, each replenished from totes stored in theitem storage and replenishment area 122.

FIGS. 1 and 2 show a system where inventory is maintained in totes 106at the shopper-accessible level 102. However, in further embodiments,the shopper-accessible level 102 may not store inventory. Instead, theshopper-accessible level may include stations, (shopper stations) anddisplay screens 112. In this embodiment, the shopper can select theirdesired items from the display screen, and totes containing those itemsare brought to the user by mobile robots 124. Once a shopper picks theirdesired item from a tote 106, the tote 106 may be carried away by themobile robot 124, and additional totes brought to the shopper 110 withtheir selected items. The shopper's selected items may be brought to theuser in totes carried by several different robots, whose movements arecoordinated by the MCS 114. This embodiment is explained in greaterdetail with respect to FIG. 16.

FIG. 3 shows a mobile robot 124 replenishing a tote 106 in an aisle 104of the shopper-accessible area 102. The MCS tracks inventory level inthe totes and subtotes and dispatches a mobile robot 124 to retrieveinventory from storage when inventory is depleted. For high velocity(fast-selling items), two totes of the same item can be located adjacentto each other to ensure the item is always available to the shopper. TheMCS 114 can use intelligent inventory handling algorithms so that highvelocity items may be stored at centrally located storage shelves forquick replenishment when the items run out at the shopper-accessiblearea 102.

The robots may travel vertically and horizontally within a space 130between the aisles 104. The operation and travel of the robots totransfer totes within the store 100 are described for example in any ofthe following patents and applications:

U.S. Pat. No. 9,139,363 issued Sep. 22, 2015, entitled “AUTOMATED SYSTEMFOR TRANSPORTING PAYLOADS”; U.S. Pat. No. 9,598,239 issued Mar. 21,2017, entitled “AUTOMATED SYSTEM FOR TRANSPORTING PAYLOADS”; U.S. PatentPublication No. 2017-0137222 published May 18, 2017, entitled “AUTOMATEDSYSTEM FOR TRANSPORTING PAYLOADS”; U.S. Patent Publication No.2017-0137223 published May 18, 2017, entitled “AUTOMATED SYSTEM FORTRANSPORTING PAYLOADS”; U.S. Patent Publication No. 2016-0355337published Dec. 8, 2016, entitled “STORAGE AND RETRIEVAL SYSTEM”; U.S.Patent Publication No. 2017-0313514 published Nov. 2, 2017, entitled“ORDER FULFILLMENT SYSTEM”; U.S. Patent Publication No. 2018-0134492published May 17, 2018, entitled “ORDER FULFILLMENT SYSTEM”; U.S.application Ser. No. 15/867,373 filed Jan. 10, 2018, entitled “SYSTEMAND METHOD OF ROBOT TASK ASSIGNMENT AND MANAGEMENT”; U.S. patentapplication Ser. No. 15/826,045 filed Nov. 29, 2017, entitled “INVENTORYMANAGEMENT SYSTEM”; and U.S. patent application Ser. No. 15/903,993filed Feb. 23, 2018, entitled “INVENTORY MANAGEMENT SYSTEM AND METHOD”.Each of the above identified patents and applications are incorporatedby reference herein in their entireties.

FIG. 4 shows a shopper 110 using reader 136 to read an RFID tag 134 foran item the shopper is purchasing from a tote 106. The reader 136 mayfor example be a finger mounted FOB RFID reader, key FOB RFID reader ora shopping wand RFID reader. Other types of electronic readers may beused for reading other types of machine readable codes on tag 134,digital or analog. Each tote location may contain a permanent RFID tagin front of it. When a shopper scans a tag 134 with her reader 136, theMCS 114 knows the location of the tote from which the shopper is pickingan item. The MCS 114 also knows what tote/item is stored at thatlocation. Thus, when a shopper uses her reader 136 to scan a tag 134,the MCS is able to determine what item the shopper has selected, and theshopper is charged for the item they select. Further details of thisprocess are explained below with respect to FIG. 14.

FIGS. 5 and 6 shows racks 128 (also called storage shelves herein)containing totes 106 being transferred from a trailer 140 or other racktransport. Racks 128 can be pre-populated with inventory totes 106 at adistribution center and sent to stores 100. Once at the store 100, theracks 128 may be automatically transported by pallet bots 142 fromtrailers 140 and docked directly to mobile robot rails extending out ofthe tote storage structure. Once docked to a transport rail, a mobilerobot 124 is able to retrieve a tote 106 containing incoming productsfrom the tote rack, as shown for example in FIG. 7. The bot will storethe tote within the tote storage structure, or alternatively directly toa position immediately accessible to shoppers. FIG. 6 also showssubtotes 106a within a tote 106.

FIG. 8 shows an alternative embodiment of the present technology.Instead of tote racks, totes 106 may be delivered to the store 100stacked on pallets 144. Thereafter, an articulated arm robot 146 may beused to move the totes 106 from the pallet to shelf locations 148 wherethe mobile robots 124 can retrieve the totes and transfer them tostorage shelves 128 within the store 100. Human laborers may be used inaddition to or instead of articulated arm robot 146.

FIG. 9 illustrates mobile robots 124 accessing any of the tote storageaisles 150 in the item storage and replenishment area 122 (not to beconfused with shopper aisles 104 in the shopper-accessible area 102).The robots 124 can travel between the tote storage aisles 150 viatransition decks 152 between the aisles 150. As noted in theabove-referenced patents and applications, the mobile robots 124 may usetwo-wheel torque steering to traverse horizontal decks 152. The mobilerobots can also move between aisles by moving on a deck in theshopper-accessible area 102.

FIGS. 10-12 show additional views of an embodiment of an automatedself-service store 100. FIG. 10 shows a side elevation view of fullyautomated retail store. FIG. 11 shows a plan or top elevation view offully automated retail store. FIG. 12 shows a front elevation view offully automated retail store.

FIG. 13 is a view of an automated distribution center 200 for shippingtotes to the automated self-service store 100. Examples where the mobilerobots 124 operate in a distribution center are disclosed in one or moreof the above-referenced patents and applications. Pallets 244 receivedfrom a manufacturer or distributor are automatically transported bypallet bots 242 to decanting stations 250. Articulated arm robots 246lift cases from pallets, automatically open them and transfer eachesinto totes 106 or subtotes 106a within the totes 106. Mobile robots 124store the totes, or immediately place them into tote racks 128 to bemoved into tractor trailers 140 for delivery to the fully automatedretail store 100.

As an alternative to racks 128, the totes may be stacked directly on topof each other on pallets 144 for delivery to the store 100. The directstacking of the totes may be preferably executed using an articulatedarm robot, or alternatively human laborers.

FIG. 14 illustrates a flow for recording selected items for chargingshoppers. The store management system (which may be the same as theMaterial Control System (MCS) 114) interacts with a client deviceapplication on the smartphone (or other computing device) of eachshopper, which is mated via Bluetooth to the reader 136. In the case theshopper does not have a smartphone, a store device will be provided tothem that is registered to them using their personal Shopping Wand. Theapp is thus the pass-through for RFID and barcode data read by the wand.As noted above, when a shopper scans a tag 134 with her reader 136, theMCS 114 knows the location of the tote from which the shopper is pickingan item. The MCS 114 also knows what tote/item is stored at thatlocation. Thus, when a shopper uses her reader 136 to scan a tag 134,the MCS is able to determine what item the shopper has selected, and theshopper is charged for the item they select.

The system may also work with items which are charged depending on theirweight. When the app sends SMS a SKU identity from a random-weight item(e.g. loose produce), the SMS looks for a scale identity, then reads theweight off that scale. When the app send SMS the barcode from arandom-dollar item, SMS simply rings up the item based on the price inthe barcode. When the app sends SMS the identity of a checkout kiosk orordering screen, SMS activates the kiosk or screen for an interactivesession with the customer. Customers can order items for immediatefulfillment by a mobile robot 124 either directly via their phone app,or via the ordering screen.

FIG. 15 illustrates an alternative configuration of store 100 withoutstorage over shopping aisles 104. This configuration permits skylightsto lighten shopping aisles 104.

FIG. 16 illustrates an embodiment including shopping stations wheretotes are presented to shoppers based on their specific order orrequest. In this embodiment, the shopper can select their desired itemsfrom the display screen 112, and totes containing those items arebrought to the shopping station 160 by mobile robots 124. Once a shopperpicks their desired item from a tote 106, the tote 106 may be carriedaway by the mobile robot 124, and additional totes brought to theshopper 110 with their selected items. The shopper's selected items maybe brought to the user in totes carried by several different robots,whose movements are coordinated by the MCS 114.

There can be multiple levels of shopping stations 160, verticallyaligned with each other at different levels. The rails on which themobile robots ride deliver the mobile robots to the appropriate level,and appropriate shopping station at the level, under the control of MCS114.

In the configuration of FIG. 16, the totes may be shifted forward andtilted towards the shopper at an angle of approximately 15-20 degrees topermit easier access into the tote. Shoppers may interact with thetouchscreen displays above the stations to retrieve their order, orspecific items they would like to buy. Access doors may be placed overthe totes to restrict shoppers to only accessing a portion of the tote;e.g. a subtote. The access doors may also be used to restrict accessinto the area of the tote while the tote is being inserted or retrievedby a bot.

FIG. 17 shows an embodiment similar to that of FIG. 16 includingshopping stations 160. However, this embodiment is implemented inside aparking structure 170 associated with the automated self-service store100. In this embodiment, shoppers may select items as described abovefrom a shopping station 160 within the parking structure 170, and theselected items are delivered by mobile robots 124 to the shoppingstations 160. According to this embodiment, the user may transfer theselected items directly to his or her car 166 (or bicycle or other modeof transport) within the parking structure 170.

There may be multiple levels in the parking structure 170, and eachlevel may have shopping stations as described above. The rails on whichthe mobile robots 124 ride deliver the mobile robots to the appropriatelevel within parking structure 170, and appropriate shopping station 160at the level, under the control of MCS 114.

FIG. 18 is an alternative configuration of way to mount racks containingtotes to the storage array. In this configuration, the racks 128 arepushed into engagement with the storage array at positions along theaisle 150. This permits many more totes to be accessible to robots 124performing exchanges of old empty totes with new full totes transportedfrom an upstream distribution center.

It should be understood that the foregoing description is onlyillustrative. Various alternatives and modifications can be devised bythose skilled in the art. For example, features recited in the variousdependent claims could be combined with each other in any suitablecombination(s). In addition, features from different embodimentsdescribed above could be selectively combined into a new embodiment.Accordingly, the description is intended to embrace all suchalternatives, modifications and variances.

We claim:
 1. An automated self-service store, comprising: a shopperaccessible level comprising inventory for selection by a shopper; anitem storage and replenishment area for storing inventory; and mobilerobots for replenishing inventory at the shopper accessible level fromthe item storage and replenishment area.
 2. The automated self-servicestore of claim 1, wherein the inventory is stored in totes, the mobilerobots replenishing totes at the shopper accessible level from the itemstorage and replenishment area.
 3. The automated self-service store ofclaim 1, further comprising display screens at the shopper accessiblelevel for describing inventory for selection by the shoppers.
 4. Theautomated self-service store of claim 1, further comprising a machinereadable tag associated with inventory at the shopper accessible level.5. The automated self-service store of claim 4, further comprising areader for use by the shopper for scanning the machine readable tag. 6.The automated self-service store of claim 5, further comprising amaterial control system for identifying a scanned machine readable tagand for identifying inventory associated with that machine readable tag.7. An automated self-service store, comprising: a shopper accessiblelevel comprising multiple locations presenting inventory for selectionby a shopper; an item storage and replenishment area above the shopperaccessible level for storing inventory; mobile robots for replenishinginventory at the shopper accessible level from the item storage andreplenishment area; and a material control system (MCS) for monitoringinventory levels of inventory at the multiple locations of the shopperaccessible level, and for directing a mobile robot of the mobile robotsto replenish inventory at a location upon detecting depleted inventoryat the location.
 8. The automated self-service store of claim 7, whereinthe shopper accessible level is inside the store.
 9. The automatedself-service store of claim 7, wherein the shopper accessible level isinside a parking structure associated with the store.
 10. The automatedself-service store of claim 7, wherein the MCS directs the mobile robotto replenish the depleted inventory with the same inventory.
 11. Theautomated self-service store of claim 7, wherein the MCS directs themobile robot to replenish the depleted inventory with inventory that isdifferent than the depleted inventory.
 12. The automated self-servicestore of claim 7, further comprising a display screen associated witheach of the multiple locations, the MCS causing display of informationon the display screens identifying the inventory at the locations. 13.The automated self-service store of claim 12, wherein the MCS updatesthe information displayed on a display screen when inventory at alocation of the multiple locations is changed.
 14. The automatedself-service store of claim 7, wherein the MCS monitors selection ofinventory from one or more of the multiple locations by a shopper andgenerates an amount owed by the shopper for the selected inventory. 15.The automated self-service store of claim 14, further comprising aninventory identifier associated with each of the multiple locations, theMCS receiving an indication of an item selected at a location by ashopper upon receiving an indication of a scan of the inventoryidentifier by a device associated with the shopper.
 16. An automatedself-service store, comprising: a shopper accessible level comprisingmultiple locations presenting inventory for selection by a shopper; anitem storage and replenishment area for storing inventory; an incomingproduct area for receiving shipments of inventory from outside theself-service store; mobile robots for transferring inventory from theincoming product area to the item storage and replenishment area, andfor transferring inventory from the item storage and replenishment areato the shopper accessible level.
 17. The automated self-service store ofclaim 16, wherein the mobile robots are further configured to transferinventory directly from the incoming product area to the shopperaccessible level.
 18. The automated self-service store of claim 16,wherein the inventory is received at the incoming product area in totesstored in racks.
 19. The automated self-service store of claim 18,wherein the mobile robots retrieve the totes directly from the racks andtransfer the totes to the item storage and replenishment area.
 20. Theautomated self-service store of claim 16, wherein the mobile robotscomprise a first group of mobile robots, and wherein the inventory isreceived at the incoming product area in totes from a delivery vehicle,the self-service store further comprising a second group of mobilerobots for transferring the totes from the delivery vehicle to theincoming product area.
 21. The automated self-service store of claim 16,wherein the inventory is received at the incoming product area in totesstored on pallets.
 22. The automated self-service store of claim 21,further comprising an articulated arm robot in the incoming product areafor transferring the totes from the pallets to a location where thetotes may be retrieved by the mobile robots.
 23. The automatedself-service store of claim 16, wherein the inventory is received at theincoming product area in totes and stored in the item storage andreplenishment area in totes, the mobile robots further transferringtotes from the item storage and replenishment area back to the incomingproduct area after the totes are emptied of inventory.
 24. The automatedself-service store of claim 16, wherein the inventory is replenishedfrom the item storage and replenishment area to the shopper accessiblelevel by transferring totes containing the inventory from the itemstorage and replenishment area to the shopper accessible level.
 25. Theautomated self-service store of claim 16, wherein the shopper accessiblelevel is inside the store.
 26. The automated self-service store of claim16, wherein the shopper accessible level is inside a parking structureassociated with the store.
 27. The automated self-service store of claim16, further comprising a material control system (MCS) for monitoringinventory levels in the totes of the shopper accessible level, and fordirecting a mobile robot of the mobile robots to replenish inventory ata location in the shopper accessible level upon detecting depletedinventory at the location.
 28. The automated self-service store of claim27, wherein the MCS further controls transfer of inventory between theincoming product area and the item storage and replenishment area. 29.The automated self-service store of claim 27, further comprising adisplay screen associated with each of multiple locations having totesin the shopper accessible level, the MCS causing display of informationon the display screens identifying the inventory at the locations. 30.The automated self-service store of claim 29, wherein the MCS updatesthe information displayed on a display screen when inventory at alocation of the multiple locations is changed.
 31. The automatedself-service store of claim 27, wherein the MCS monitors selection ofinventory from one or more of the multiple locations by a shopper andgenerates an amount owed by the shopper for the selected inventory. 32.The automated self-service store of claim 31, further comprising aninventory identifier associated with each of the multiple locations, theMCS receiving an indication of an item selected at a location by ashopper upon receiving an indication of a scan of the inventoryidentifier by a device associated with the shopper.